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WO2004099474A2 - Dispersion de precurseur de polymere contenant une micropulpe et procede de preparation de la dispersion - Google Patents

Dispersion de precurseur de polymere contenant une micropulpe et procede de preparation de la dispersion Download PDF

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Publication number
WO2004099474A2
WO2004099474A2 PCT/US2004/013926 US2004013926W WO2004099474A2 WO 2004099474 A2 WO2004099474 A2 WO 2004099474A2 US 2004013926 W US2004013926 W US 2004013926W WO 2004099474 A2 WO2004099474 A2 WO 2004099474A2
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WIPO (PCT)
Prior art keywords
polymer
micropulp
polymer precursor
dispersion
precursor
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PCT/US2004/013926
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WO2004099474A3 (fr
Inventor
John Chu Chen
Arnold Frances
Sam Louis Samuels
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EIDP Inc
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EI Du Pont de Nemours and Co
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Priority to BRPI0410525-7A priority Critical patent/BRPI0410525A/pt
Priority to JP2006514290A priority patent/JP5230936B2/ja
Priority to CN2004800119068A priority patent/CN1784472B/zh
Priority to DE602004003232T priority patent/DE602004003232T2/de
Priority to EP04751343A priority patent/EP1620508B1/fr
Priority to CA2522746A priority patent/CA2522746C/fr
Priority to MXPA05011668A priority patent/MXPA05011668A/es
Publication of WO2004099474A2 publication Critical patent/WO2004099474A2/fr
Publication of WO2004099474A3 publication Critical patent/WO2004099474A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/91—Polymers modified by chemical after-treatment
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F283/00—Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass C08G
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F283/00—Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass C08G
    • C08F283/04—Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass C08G on to polycarbonamides, polyesteramides or polyimides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/78—Preparation processes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/60—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds

Definitions

  • This invention is directed to a process for incorporating a micropulp in a polymer precursor, the resulting dispersion, polymer made from that dispersion, and articles made from that polymer.
  • Pulps because of their fibrous nature, can be difficult to uniformly disperse in other materials. Many polymers can be enhanced by the addition of a pulp, and even very small additions of pulp can have a positive effect.
  • United States patent application 10/295,455 filed November 15, 2002 relates to a process for producing micropulp in a liquid component and discloses that liquid component can be an aqueous liquid, one or more liquid polymers, one or more solvents, or a combination thereof.
  • compositions made from a dispersion of micropulp in a liquid component selected from the group consisting of an aqueous liquid, one or more liquid polymers, one or more solvents, or a combination thereof.
  • a liquid component selected from the group consisting of an aqueous liquid, one or more liquid polymers, one or more solvents, or a combination thereof.
  • 2003 relates to a liquid nail polish compositions containing micropulp wherein the micropulp is made in a nail polish resin system comprising a resin and a solvent.
  • United States patent application 60/462,236 filed on April 11 , 2003 relates to coating compositions and molded products containing acetoacetylated polyvinyl polymers and discloses a method of producing a molded article comprising mixing micropulp with a composition comprising acetoacetylated polyvinyl polymers, melting the polymers and then making a molded shape from the mixture of micropulp and polymer.
  • This invention is directed to a polymer precursor dispersion for use in making a polymer that is a solid at room temperature, comprising a polymer precursor comprising an addition monomer, a condensation monomer, a prepolymer, or a polymer modifier; and a micropulp having a volume average length of from 0.01 to 100 micrometers, the micropulp comprising 0.01 to 50 weight percent of the dispersion.
  • This invention is further directed to a method of incorporating a micropulp in a polymer precursor for making a polymer that is a solid at room temperature, comprising contacting organic fiber, a polymer precursor and a solid component, agitating the organic fiber, the polymer precursor, and the solid component to transform the organic fiber into a micropulp having a volume average length of from 0.01 to 100 micrometers dispersed in the polymer precursor, and optionally removing the solid component.
  • This invention relates to a polymer precursor dispersion containing a micropulp and a method of incorporating a micropulp in a polymer precursor for making a polymer.
  • This polymer precursor dispersion can then be reacted, polymerized, or otherwise combined with a polymer to create a polymer having dispersed therein a micropulp.
  • the polymer precursor dispersion of the present invention is for use in making a polymer that is a solid at room temperature.
  • the dispersion comprises a polymer precursor comprising an addition monomer, a condensation monomer, a prepolymer, or a polymer modifier.
  • the dispersion further comprises a micropulp having a volume average length of from 0.01 to 100 micrometers, the micropulp comprising 0.01 to 50 weight percent of the dispersion.
  • micropulp is a processed organic fiber having a volume average length ranging from 0.01 to 100 micrometers, preferably 0.1 to 50 micrometers. Such micropulps generally have an average surface area ranging from 25 to 500 square meters per gram.
  • the micropulp of the present invention is a fibrous organic material that includes an intermeshed combination of two or more webbed, dendritic, branched, mushroomed or fibril structures.
  • Micropulp is made by contacting an organic fiber with a medium comprised of a liquid component and a solid component and then agitating the combination to size reduce and modify the organic fiber.
  • the organic fiber used as a starting material can include pulp, short fiber, fibrids or mixtures of these forms. Through this treatment the micropulp is uniformly dispersed in the liquid component.
  • Pulps can be made by refining short fibers between rotating discs to cut and shear the fibers into smaller pieces. Pulp particles differ from short fibers by having a multitude of fibrils or tentacles extending from the body of each pulp particle. These fibrils or tentacles provide minute hairlike anchors for reinforcing composite materials and cause the pulp to have a very high surface area.
  • a particularly useful starting material is aramid pulp, which is well known in the art and can be made by refining aramid fibers to fibrillate the short pieces of aramid fiber material. Such pulps have been reported to have a surface area in the range of 4.2 to 15 meters 2 /gram and a Kajaani weight average length in the range of 0.6 to 1.1 millimeters (mm).
  • Such pulps have high volume average length, compared to the micropulp.
  • Style 1 F543 aramid pulp available from E. I. du Pont de Nemours and Company has a Kajaani weight average length in the range of 0.6 to 0.8 mm, and when laser defraction is used to measure this pulp the volume average length is 500 to 600 micrometers (0.5 to 0.6 mm).
  • An alternate method of making aramid pulp directly from a polymerizing solution is disclosed in U.S. Patent No. 5,028,372.
  • Short fiber (sometimes called floe) is made by cutting continuous filament into short lengths without significantly fibrillating the fiber. Short fiber length typically ranges from about 0.25 mm to 12 mm.
  • Short fibers suitable for use in the present invention are the reinforcing fibers disclosed in U.S. Patent No. 5,474,842.
  • Fibrids are non-granular film-like particles having an average maximum length or dimension in the range of 0.2 to 1 mm with a length-to- width aspect ratio in the range of 5:1 to 10:1. The thickness dimension is on the order of a fraction of a micron.
  • Aramid fibrids are well known in the art and can be made in accordance with the processes disclosed in U.S. Patent Nos. 5,209,877, 5,026,456, 3,018,091 and 2,999,788.
  • the processes typically include adding a solution of organic polymer in solvent to another liquid, that is a non-solvent for the polymer but is miscible with the solvent, and applying vigorous agitation to cause coagulation of fibrids.
  • the coagulated fibrids are wet milled, separated, and dried to yield clumps of fibrids having a high surface area; the clumps are then opened to yield a particulate fibrid product.
  • Micropulp used in the present invention can be made from an organic fiber comprised of aliphatic polyamides, polyesters, polyacrylonitriles, polyvinyl alcohols, polyolefins, polyvinyl chlorides, polyvinylidene chlorides, polyurethanes, polyfluorocarbons, phenolics, polybenzimidazoles, polyphenylenetriazoles, polyphenylene sulfides, polyoxadiazoles, polyimides, aromatic polyamides, or a mixture thereof.
  • Especially useful polymers are made from aromatic polyamides, polybenzoxadiazole, polybenzimidazole, or a mixture thereof.
  • organic fibers suitable for use in the present invention include natural fibers, such as cellulose, cotton, silk, and/or wool fibers.
  • Some commercially available fibers useful as a starting material for micropulp include ZYLON ® PBO-AS (poly(p-phenylene-2,6- benzobisoxazole)) fiber, ZYLON ® PBO-HM (poly(p-phenylene-2,6- benzobisoxazole)) fiber, DYNEEMA ® SK60 and SK71 ultra high strength polyethylene fiber, all supplied by Toyobo, Japan; Celanese VECTRAN ® HS pulp, EFT 1063-178, supplied by Engineering Fibers Technology, Shelton, Connecticut; CFF Fibrillated Acrylic Fiber supplied by Arlington Fibers, Inc., Pace, Florida; and Tiara Aramid KY-400S Pulp supplied by Daicel Chemical Industries, Ltd., 1 Teppo-Cho, Sakai City Japan.
  • the preferred organic fibers comprise fibers made from the aromatic polyamide polymers poly(p-phenylene terephthalamide) and/or poly(m-phenylene isophthalamide). Such fibers are also known as aramid fibers. As used herein, "aramid” is meant a polyamide wherein at least 85% of the amide (-CONH-) linkages are attached directly to two aromatic rings. Additives can be used with the aramid.
  • Preferred aromatic polyamide organic fibers are known under the trademark KEVLAR ® fibers, KEVLAR ® aramid pulp, style 1 F543; 1.5 mm KEVLAR ® aramid floe style 6F561 ; and NOMEX ® aramid fibrids style F25W. All of these are available from E. I. du Pont de Nemours and Company, Wilmington, Delaware. Polymer Precursor
  • the polymer precursor of this invention can be an addition monomer, a condensation monomer, or a prepolymer or a polymer modifier.
  • Addition monomers are well known in the art and a non-limiting example is methyl methacrylate, which can polymerize with itself to make poly(methyl methacrylate), or with other monomers such as ethyl acrylate to make an acrylate compolymer.
  • Other addition monomers useful in this invention include vinyl monomers such as styrene, acrylonitrile, and vinyl chloride.
  • Condensation monomers are also well known in the art and for the purposes of this invention can be one or more of the reactants used in a condensation reaction to form a monomer or polymer, or one of the actual monomers formed by the reactants.
  • a condensation monomer is ethylene glycol, which can be reacted with dimethyl terephalate and used to form the polymer polyethylene terephthalate.
  • Other condensation monomers useful in this invention include diethylene glycol, 1 ,3 propane diol, 1 ,4 butane diol, or cyclohexane dimethanol.
  • a prepolymer is a partially polymerized polymer that has low molecular weight and can be further polymerized to a higher molecular weight.
  • a prepolymer By partially polymerized it is meant the reacting monomers are not present in the proper stoichiometric ratio for fully polymer chain development, which prevents the generation of high molecular weight.
  • Such proper stoichiometric ratio of monomers is normally 1 :1 for many polymers.
  • Such prepolymers have low molecular weight, meaning they are only able to form very short chains having only a few repeat units, normally less than about 20 repeat units, and typically less than about 10 repeat units.
  • a non-limiting example of a prepolymer is a polyamide acid.
  • a polymer is then made from the dispersion by first adjusting the stoichiometric ratio of the prepolymer by adding additional monomer. The polymer is then made by imidizing the prepolymer by heat to make a polyimide polymer.
  • Other useful prepolymers can include any low molecular weight oligomers that can subsequently be polymerized, such as a polyester oligomer.
  • a prepolymer can also be an emulsified polymer dispersion that is further reacted to form a useful polymer. For example, some acid copolymers can be reacted with metal salts to form intractable polymer compositions.
  • Micropulp can be incorporated into these polymers by first producing the micropulp in an emulsion of the acid copolymer. The resulting polymer precursor dispersion can then be used to form the polymer.
  • a non-limiting example of a suitable acid copolymer is an ethylene copolymer containing the polar comonomer methacrylic acid.
  • the polymer precursor can also be a polymer modifier.
  • a polymer modifier is a material that is compatible with and substantially remains in the final polymer.
  • the polymer modifier is not meant to be a solvent for the final polymer or a polymer itself, but modifies the final polymer in some way.
  • a polymer modifier can be an additive such as a plasticizer for the polymer or a curing agent for the polymer.
  • Other types of polymer modifier can function, for example, as a property enhancer, a processing aid, or a surface lubricating agent.
  • a non-limiting example of a polymer modifier is a liquid fatty acid such as oleic acid, which can be combined with an ethylene-copolymer-based acid copolymer or ionomer while it is being mixed and neutralized.
  • This polymer modifier oleate enhances the resilience of the polymer.
  • the preferred polymer precursors used in this invention have a viscosity at room temperature of less than 10,000 centipoise. Above 10,000 centipoise, the liquid viscosity can be too high to adequately incorporate and process the organic fiber into a micropulp.
  • the shape of the solid component that is contacted with the polymer precursor and the organic fiber is not critical and can include spheroids, diagonals, irregularly shaped particles or combinations thereof. Spheroids are preferred.
  • the maximum average size of the solid component can range from 10 micrometers to 127,000 micrometers, and it depends upon the type of agitating device used to produce the micropulp. For example, when attritors are used, the size generally varies from about 0.6 mm diameter to about 25.4 mm. When media mills are used, the diameter generally varies from about 0.1 to 2.0 mm, preferably from 0.2 to 2.0 mm.
  • the diameter generally varies from about 3.2 mm (1/8") to 76.2 mm (3.0 inches), preferably from 3.2 mm (1/8") to 9.5 mm (3/8 inches).
  • the solid component is generally chemically compatible with the liquid component and typical solid components are made from glass, alumina, zirconium oxide, zirconium silicate, cerium- stabilized zirconium oxide, fused zirconia silica, steel, stainless steel, sand, tungsten carbide, silicon nitride, silicon carbide, agate, mullite, flint, vitrified silica, borane nitrate, ceramics, chrome steel, carbon steel, cast stainless steel, plastic resin, or a combination thereof.
  • plastic resins suitable for the solid component include polystyrene, polycarbonate, and polyamide.
  • glass suitable for the solid component includes lead-free soda lime, borosilicate and black glass. Zirconium silicate can be fused or sintered.
  • the most useful solid component are balls made of carbon steel, stainless steel, tungsten carbide or ceramic. If desired, a mixture of balls having the same size but different composition or having varying sizes can also be used. Ball diameter can range from about 0.1 millimeters to 76.2 millimeters and preferably from about 0.4 millimeters to 9.5 millimeters, more preferably from about 0.7 millimeters to 3.18 millimeters. Solid components are readily available from various sources, some of which include Glenn Mills, Inc., Clifton, New Jersey; Fox Industries, Inc., Fairfield, New Jersey; and Union Process, Akron, Ohio. Polymer and Articles
  • the polymer precursor dispersion can be reacted, polymerized or otherwise processed or converted into a polymer containing micropulp using conventional methods.
  • the polymer having a micropulp dispersed therein, made from the polymer precursor dispersion of this invention, can be any type of thermoplastic, thermoset, or other type of polymer as long as it is a solid at room temperature.
  • the polymer can be further processed in any conventional manner, such as spun, extruded, shaped or molded into various articles (including fibers and films) or parts. Since the process of incorporating the micropulp into the polymer almost assures the micropulp will be well dispersed, the shaped articles or parts will have uniform mechanical properties. The extremely small size of the micropulp substantially eliminates the pluggage problems encountered when shaping larger prior art pulps
  • the method of incorporating a micropulp in a polymer precursor for making a polymer that is a solid at room temperature comprises a contacting step, an agitating step, and optionally a removing step.
  • the contacting step comprises contacting organic fiber, a polymer precursor and a solid component.
  • the agitating step comprises agitating the organic fiber, the polymer precursor, and the solid component to transform the organic fiber into a micropulp having a volume average length of from 0.01 to 100 micrometers dispersed in the polymer precursor.
  • the optional removing step comprises optionally removing the solid component.
  • micropulp is made in a polymer precursor that is the liquid component in which the organic fiber is processed.
  • a polymer precursor that is the liquid component in which the organic fiber is processed.
  • Such polymer precursors if liquid at normal temperatures, can be used neat without solvent. However, if the polymer precursor is solid, or too viscous, the polymer precursor can be solutioned in a solvent and used in that fashion. If the polymer precursor is used without solvent, it is preferred the micropulp be present in an amount of 0.01 to 10 weight percent, based on the total weight of the polymer precursor and micropulp. If a solvent is added to the polymer precursor, the preferred amount of organic fiber present is 0.01 to 10 weight percent based on the total amount of polymer precursor, fiber, and solvent present. However, a concentrated polymer precursor can be made by removing all or a portion of the solvent from the dispersion after the micropulp is formed. In this manner a polymer precursor having concentrations of 50 weight percent micropulp or higher can be formed.
  • the organic fiber is processed, in the presence of a polymer precursor, into micropulp having a volume average length ranging from 0.01 micrometers to 100 micrometers, and an average surface area of from 25 to 500 square meters per gram. This is accomplished by contacting and agitating the organic fibers with a liquid polymer precursor and a solid component. Agitating the organic fibers in the presence of solid components size-reduce and modify the organic fibers. The organic fibers repeatedly come in contact with and are masticated by the solid components maintained in an agitated state by, for example, one or more stirring arms of an attritor.
  • the size reduction in the process of this invention results from both longitudinal separation of the organic fibers into substantially smaller diameter fibers along with a length reduction. Average fiber length reductions of one, two or even greater orders of magnitude can be attained.
  • the agitating step is continued for sufficient duration to transform the organic fibers into the micropulp. Moreover, it may be desirable to incrementally transform the organic fiber into the micropulp in several passes by repeatedly passing the medium containing the organic fibers through the agitation device. Agitating Step
  • the polymer precursor dispersion containing micropulp is made by agitating a solid component and a liquid polymer precursor or polymer precursor solution, the surface of the micropulp is fully wetted and uniformly distributed in the dispersion, with minimal agglomerations or clumps.
  • the processing of organic fibers into micropulp can be accomplished in any one or more types of agitating devices, including an attritor or a mill, and the devices can be batch or continuously operated.
  • Batch attritors are known in the art and those such as attritor models 01 , 1-S, 10-S, 15-S, 30-S, 100-S and 200-S supplied by Union Process, Inc., of Akron, Ohio are well suited for the process of the present invention.
  • Another supplier of such devices is Glen Mills Inc. of Clifton, New Jersey.
  • Media mills are supplied by Premier Mills, Reading Pennsylvania, and some of their suitable mills include the Supermill HM and EHP models.
  • the preferred agitation device is an attritor, and preferably the solid component is poured into the agitation chamber of the attritor and then agitated by the stirring arms, after which the premix of organic fibers and liquid component is then poured into the chamber.
  • the solid component is circulated during the agitating step through an external passage that is typically connected near the bottom and the top of the chamber for a vertical media mill.
  • the rate at which the solid component is agitated depends upon the physical and chemical make-up of the organic fibers being transformed, the size and type of the solid component, the duration of the transformation, as well as the size of the micropulp desired.
  • the agitation of the solid component in an attritor is generally controlled by the tip speed of the stirring arms and the number of stirring arms provided.
  • a typical attritor has four to twelve arms and the tip speed of the stirring arms generally range from about 150 fpm to about 1200 fpm (about 45 meters per minute to about 366 meters per minute).
  • the preferred attritor has six arms and is operated at a tip speed in the range of about 200 fpm to about 1000 fpm (about 61 meters per minute to about 305 meters per minute) and more preferably from about 300 fpm to about 500 fpm (about 91 meters per minute to about 152 meters per minute).
  • the tip speeds of the stirring arms generally range from about 1500 fpm to about 3500 fpm (about 457 meters per minute to about 1067 meters per minute) and preferably from about 2000 fpm to about 3000 fpm (about 610 meters per minute to about 914 meters per minute).
  • Any excessive heat generated in the agitation process is normally removed by use of a cooling jacket on the agitation chamber.
  • the amount of solid component used in the agitating chamber is called the load, and is measured by the bulk volume and not the actual volume of the agitating chamber. Thus, 100% load means about 60% of the chamber volume since substantial air pockets exist within the solid component.
  • the load for the media mill or an attritor ranges from 40% to 90%, preferably from 75% to 90% based on the full load.
  • the load for the ball mill ranges from 30% to 60% based on the full load.
  • the percent load is determined by first totally filling the chamber with the solid component to determine the weight of a full load. The desired load is then measured by weight as a percent of the full load.
  • the solid component is removed to form a dispersion of the micropulp in the polymer precursor.
  • the solid component remains in the agitating chamber.
  • some of the conventional separation processes include a mesh screen having openings that are small enough for the polymer precursor dispersion containing the micropulp to pass through while the solid component is retained on the mesh screen. Thereafter, the dispersion can be used directly.
  • the dispersion of the preferred micropulp when visually observed on a 254 microns (10 mils) draw-down on a glass, contains negligible grit or seed.
  • volume average length measurements were made using laser diffraction using a Beckman LS Particle Size Analyzer. Single point nitrogen BET surface area measurements were made using a Strohlein Area Meter. As used herein, the volume average length is calculated by the following equation:
  • Example 1 This example illustrates a method for making a polymer precursor dispersion of micropulp in a condensation monomer, and then polymerizing the condensation monomer to make a polymer.
  • the condensation monomer is ethylene glycol and the final polymer is a polyester.
  • the polymer precursor dispersion was prepared by adding 300 grams of poly(paraphenylene terephthalamide) pulp (KEVLAR ® pulp Merge 1 F543 available from E. I. du Pont de Nemours and Company) to 12,908 grams of ethylene glycol in a tank to form a dispersion of pulp in ethylene glycol having a pulp content of 2.27 weight percent.
  • the pulp was dispersed using a high speed disperser with a cowles blade running at a speed high enough to create a vortex in the dispersion.
  • the dispersion was then recirculated through a 1.5 liter Premier SML Supermill.
  • the mill was run with a circumferential disk speed of 2400 feet per minute (732 meters per minute) and after 8 hours of recirculation a sample of the dispersion of micropulp in ethylene glycol was collected.
  • This Sample 1 had a micropulp content of 2.27 weight percent.
  • the remaining dispersion of micropulp in ethylene glycol was diluted with additional ethylene glycol until the micropulp content was 1.85 weight percent and this dispersion was recirculated for another 8 hours and collected, forming Sample 2 having a micropulp content of 1.85 weight percent.
  • the volume average fiber length for these samples were about 5 and 3 micrometers, respectively, for the 8 and 16 hour samples. Samples are summarized in Table 1.
  • the polymer precursor dispersion Sample 1 having 2.27 weight percent micropulp in ethylene glycol, was used to make a polyester polymer having a micropulp dispersed therein.
  • the polymer was made on a 40 pound (18 kilogram) horizontal autoclave with an agitator, vacuum jets, and a monomer distillation still located above the clave portion of the autoclave.
  • the monomer distillation still was charged with 40 pounds (18 kilograms) of dimethyl terephthalate (DMT), 26 pounds (12 kilograms) of ethylene glycol, and 8.8 pounds (4 kilograms) of Sample 1.
  • DMT dimethyl terephthalate
  • Tetrapropyl titanate was used as both the exchange and polymerization catalyst.
  • the temperature of the still was gradually raised to 240°C and approximately 6000 grams of methanol distillate was recovered.
  • the molten prepolymer was then dropped from the monomer still to the clave portion of the autoclave. There the prepolymer was mixed, agitated, and polymerized by increasing the temperature to approximately 280°C. The pressure was reduced to approximately 1 mm Hg (133 Pa) over about 2 hours and the material was held at these conditions for approximately 4 hrs. The polymer was extruded through a 3 hole casting plate, quenched and cut.
  • the polymer precursor of dispersion Sample 2 having 1.85 weight percent micropulp in ethylene glycol, was then used to make a polyester polymer having a micropulp dispersed therein by repeating the above steps with the exception that only 1 pound (0.45 kilograms) of Sample 2 was added to the monomer distillation still.
  • the polymer precursor of dispersion Sample 2 having 1.85 weight percent micropulp in ethylene glycol, was then used to make a polyester polymer having a micropulp dispersed therein by repeating the above steps with the exception that 2.2 pounds (1 kilogram) of Sample 2 was added to the monomer distillation still.
  • Example 2 This example illustrates a method for making a polymer precursor dispersion of micropulp in a condensation monomer, and then polymerizing the condensation monomer to make a polymer.
  • the condensation monomer is 1 ,4-butanediol and the final polymer is a copolyetherester.
  • a series of samples of a nominal 1.5 weight percent micropulp dispersed in 1 ,4-butanediol was made by making a first mixture by adding 136.8 grams of poly(paraphenylene terephthalate) pulp (KEVLAR ® pulp, Merge 1 F543) to 8986 grams of 1 ,4-butanediol and running this through the 1.5 liter Premier media mill as in Example 1.
  • KEVLAR ® pulp poly(paraphenylene terephthalate) pulp
  • Copolyetherester polymers were made from selected samples from
  • the ingredients from Table 2b were placed in an agitated flask fitted for distillation and a stainless steel stirrer with a paddle cut to conform with the internal radius of the flask was positioned about 2 mm from the bottom of the flask.
  • the air in the flask was replaced with nitrogen by applying vacuum, and then re-pressurized with nitrogen.
  • the flask was placed in a Woods metal bath at 155°C, and agitation initiated. The bath temperature was increased to 210°C, and it was held at 210°C for 40 minutes.
  • Poly(tetramethyleneether) glycol number average molecular weight of about 975 27.0 Dimethyl Terephthalate 24.2
  • Micropulp content (wt %) 0 0.5 0.5 1.5 0.5
  • This example illustrates a method for making a polymer precursor dispersion of micropulp in an addition monomer, and then polymerizing the addition monomer to make a polymer.
  • the addition monomer is methyl methacrylate and the final polymer is a poly(methyl methacrylate).
  • the polymer precursor dispersion containing micropulp was produced using a 1.5 liter Premier mill.
  • the mix tank was filled with 7840 grams of methyl methacrylate and 160 grams of poly(paraphenylene terephthalamide) pulp (KEVLAR ® pulp, Merge 1 F543).
  • KEVLAR ® pulp poly(paraphenylene terephthalamide) pulp
  • Example 2 due to capacity limitations of the mix tank, while the first mixture was running through the mill a second mixture of an additional 4704 grams of methyl methacrylate and 96 grams of pulp were added to the mix tank and this became combined with the first mixture.
  • the combined mixtures were collected together after a single pass and this first polymer precursor dispersion containing micropulp was designated Sample 10 and had a volume average length of 100 micrometers.
  • This example illustrates a method for making a polymer precursor dispersion of micropulp in a prepolymer, and then polymerizing the prepolymer to make a polymer having a micropulp dispersed therein.
  • the prepolymer is an emulsion and the final polymer is a copolymer of ethylene and methacrylic acid.
  • the polymer precursor dispersion containing micropulp was produced in a 1.5 liter Premier mill.
  • the mix tank was filled with 3908 grams of AQUASEAL ® 1243 and 120.8 grams of wet poly(paraphenylene terephthalamide) pulp, available from E. I. du Pont de Nemours and Company as KEVLAR ® pulp, Merge 1 F361 (this is 50% water, so 60.4 grams of actual pulp were actually added).
  • AQUASEAL ® is an aqueous emulsion of approximately 25 percent by weight of a copolymer of ethylene and acrylic acid (19% by weight) and 75 percent demineralized water containing approximately 10 percent ammonium hydroxide.
  • Samples 14 -16 were recirculated through the mill with 150 ml samples designated Samples 14 -16, respectively, of the polymer precursor dispersion taken after 2, 4, and 6 hours of recirculation. The remainder was collected after 9 hours of recirculation and this was designated Sample 17. Samples are summarized in Table 4.
  • Polymers containing micropulp were made from each of the samples by injecting the polymer precursor dispersion into an extruder containing a molten copolymer of ethylene and methacrylic acid (19% by weight) that was partially neutralized (approximately 60%) with zinc ions.
  • the water was vacuum extracted from the extruder and a copolymer having a micropulp dispersed therein was extruded in the form of pellets.
  • Example 5 This example illustrates a method for making a polymer precursor dispersion of micropulp in a polymer modifier, and then incorporating the polymer modifier in the polymer to make a polymer having micropulp dispersed therein.
  • the polymer modifier is oleic acid and the final polymer is a copolymer of ethylene and methacrylic acid.
  • the polymer precursor dispersion containing micropulp of this example was produced in a larger 15 liter Premier mill.
  • Poly(paraphenylene terephthalamide) pulp Kevlar® pulp Merge 1 F543
  • Two polymers containing micropulp were made by injecting the 9-pass polymer precursor dispersion (Sample 22) into an extruder containing each individual polymer.
  • the first polymer contained molten ionomers of a copolymer of ethylene and methacrylic acid (19% by weight) and the second polymer contained molten ionomers of a copolymer of ethylene, n-butylacrylate (23.5 % by weight) and methacrylic acid (9% by weight) that was partially neutralized with magnesium hydroxide.
  • the water was vacuum extracted from the extruder and a polymer having a micropulp dispersed therein was extruded in the form of pellets.
  • Polymer containing micropulp were made by injecting the 9-pass polymer precursor dispersion (Sample 22) into an extruder containing molten ionomers of a copolymer of ethylene and methacrylic acid (19% by weight) and a copolymer of ethylene, n-butylacrylate (23.5 % by weight) and methacrylic acid (9% by weight) that was partially neutralized with magnesium hydroxide.
  • the water was vacuum extracted from the extruder and a copolymer having a micropulp dispersed therein was extruded in the form of pellets.
  • This example illustrates a method for making a polymer precursor dispersion of micropulp in a prepolymer, and then polymerizing the prepolymer to make a polymer having a micropulp dispersed therein.
  • the prepolymer is a polyamide acid and the final polymer is polyimide.
  • This example also illustrates one method by which a solvent can be added to the polymer precursor and then later removed after the micropulp is formed in the polymer precursor.
  • the polymer precursor dispersion containing micropulp was produced using a 1.5 liter Premier mill.
  • the mix tank was filled with the polyamide acid prepolymer mixture containing DMAc and poly(paraphenylene terephthalamide) pulp (KEVLAR ® pulp Merge 1 F543). Additional DMAc was added to the mixture.
  • the final mixture was approximately 10.1 kilograms which contained about 7.5 percent by weight polyamide acid prepolymer, about 1 percent by weight poly(paraphenylene terephthalamide) pulp (KEVLAR ® pulp Merge 1 F543), and about 91.5 percent by weight DMAc.
  • a polyimide polymer having micropulp dispersed therein is made from the prepolymer dispersion containing micropulp.
  • the prepolymer is first "finished” by the addition of small amount of pyromellitic dianhydride with the goal being to bring the molar diamine/dianhydride ratio close to 1 :1 to increase molecular weight and viscosity.
  • Target final viscosity is between 200 - 5000 poise.
  • a liquid film is then cast on a smooth surface using a die casting process. Initial temperatures while the liquid film is on the cast surface ramp up through an oven between 60°C - 200°C over 5 - 60 minutes. The casting process removes DMAc solvent and creates a freestanding film containing 70 - 90% solids of micropulp and polyamide acid prepolymer.
  • the prepolymer film is then converted to a polyimide polymer film having micropulp dispersed therein by placing the film in a high temperature oven for imidization at 200 to 400°C for 5 to 60 minutes.
  • This example illustrates the problems experienced with attempting to incorporate a micropulp into a high viscosity liquid polymer.
  • EPON 828 has a viscosity of 11 ,000 centipoise at room temperature and consequently was too viscous to process in the mill so it was not possible to make a dispersion of micropulp in this highly viscous resin.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Processes Of Treating Macromolecular Substances (AREA)
  • Polymerisation Methods In General (AREA)
  • Artificial Filaments (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)

Abstract

La présente invention concerne une dispersion de précurseur de polymère destinée à être utilisée pour produire un polymère qui est solide à température ambiante et se rapporte également à un procédé de production de ce dernier dans lequel la dispersion comprend un précurseur de polymère comprenant un monomère d'addition, un monomère de condensation, un prépolymère ou un modificateur de polymère et de 0,01 à 50 pour cent en poids d'une micropulpe ayant une longueur moyenne en volume comprise entre 0,01 et 100 microns.
PCT/US2004/013926 2003-05-02 2004-04-30 Dispersion de precurseur de polymere contenant une micropulpe et procede de preparation de la dispersion Ceased WO2004099474A2 (fr)

Priority Applications (7)

Application Number Priority Date Filing Date Title
BRPI0410525-7A BRPI0410525A (pt) 2003-05-02 2004-04-30 dispersão de precursor polimérico, artigo moldado e método de incorporação de micropolpa
JP2006514290A JP5230936B2 (ja) 2003-05-02 2004-04-30 マイクロパルプ含有ポリマー前駆体分散液およびとその分散液の製造方法
CN2004800119068A CN1784472B (zh) 2003-05-02 2004-04-30 含有微浆的聚合物前体分散体及制备该分散体的方法
DE602004003232T DE602004003232T2 (de) 2003-05-02 2004-04-30 Eine mikropulpe enthaltende polymervorläuferdispersion und herstellungsverfahren dafür
EP04751343A EP1620508B1 (fr) 2003-05-02 2004-04-30 Dispersion de precurseur de polymere contenant une micropulpe et procede de preparation de la dispersion
CA2522746A CA2522746C (fr) 2003-05-02 2004-04-30 Dispersion de precurseur de polymere contenant une micropulpe et procede de preparation de la dispersion
MXPA05011668A MXPA05011668A (es) 2003-05-02 2004-04-30 Dispersion precursora de polimero que contiene micropulpa y metodo para la elaboracion de la dispersion.

Applications Claiming Priority (2)

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US10/428,294 2003-05-02
US10/428,294 US7015274B2 (en) 2003-05-02 2003-05-02 Polymer precursor dispersion containing a micropulp and method of making the dispersion

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WO2004099474A3 WO2004099474A3 (fr) 2005-03-31

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BR (1) BRPI0410525A (fr)
CA (1) CA2522746C (fr)
DE (1) DE602004003232T2 (fr)
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Cited By (2)

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US7521493B2 (en) 2005-01-10 2009-04-21 E. I. Du Pont De Nemours And Company Slurries containing microfiber and micropowder, and methods for using and making same
US9518163B2 (en) 2008-05-26 2016-12-13 Semmes, Inc. Reinforced polymer foams, articles and coatings prepared therefrom and methods of making the same

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US7144958B2 (en) 2003-05-21 2006-12-05 E. I. Du Pont De Nemours And Company Articles prepared from compositions modified with organic fiber micropulp
US20090298372A1 (en) * 2003-06-05 2009-12-03 E. I. Du Pont De Nemours And Company Article comprising ionomer and polyamide
US20070149656A1 (en) * 2005-12-23 2007-06-28 3M Innovative Properties Company Sprayable mining liner composition
US7790276B2 (en) * 2006-03-31 2010-09-07 E. I. Du Pont De Nemours And Company Aramid filled polyimides having advantageous thermal expansion properties, and methods relating thereto
CN101980860B (zh) 2008-04-04 2014-01-29 纳幕尔杜邦公司 具有改善的流体不可渗透性的复合材料面板
WO2016015407A1 (fr) * 2014-07-29 2016-02-04 京东方科技集团股份有限公司 Matériau fonctionnel, procédé de préparation associé, structure tactile, et dispositif d'affichage tactile
WO2016015408A1 (fr) 2014-07-29 2016-02-04 京东方科技集团股份有限公司 Materiau fonctionnel, procede de preparation associe, ecran a diodes electroluminescentes organiques

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US4439561A (en) * 1982-03-24 1984-03-27 Union Carbide Corporation Sealant composition and method
JPS58191296A (ja) 1982-05-04 1983-11-08 ダイセル化学工業株式会社 紙用塗料組成物
JPH0368649A (ja) * 1989-08-09 1991-03-25 Nippon Carbide Ind Co Inc 熱硬化性樹脂成形材料組成物
JPH0328243A (ja) 1989-10-18 1991-02-06 Sumitomo Rubber Ind Ltd 硬質ゴム組成物
JPH03180506A (ja) 1989-12-04 1991-08-06 Mitsui Petrochem Ind Ltd 合成パルプの製造方法
WO1993001333A1 (fr) * 1991-07-02 1993-01-21 E.I. Du Pont De Nemours And Company Agents epaississants a base de fibrides
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FR2716887B1 (fr) * 1994-03-01 1996-04-26 Atochem Elf Sa Polymères renforcés de microfibrilles de cellulose, latex, poudres, films, joncs correspondants, et leurs applications.
FR2738816B1 (fr) * 1995-09-20 1997-11-28 Aerospatiale Monomeres acryliques durcissables sous rayonnement x ou electrons, utilisables pour la fabrication de materiaux composites a renfort fibreux
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7521493B2 (en) 2005-01-10 2009-04-21 E. I. Du Pont De Nemours And Company Slurries containing microfiber and micropowder, and methods for using and making same
US9518163B2 (en) 2008-05-26 2016-12-13 Semmes, Inc. Reinforced polymer foams, articles and coatings prepared therefrom and methods of making the same

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MXPA05011668A (es) 2005-12-15
JP2007521357A (ja) 2007-08-02
US7297739B2 (en) 2007-11-20
US20060094799A1 (en) 2006-05-04
BRPI0410525A (pt) 2006-06-20
DE602004003232T2 (de) 2007-09-06
DE602004003232D1 (de) 2006-12-28
CN1784472B (zh) 2011-03-02
US7015274B2 (en) 2006-03-21
WO2004099474A3 (fr) 2005-03-31
CA2522746C (fr) 2010-03-23
KR20060009881A (ko) 2006-02-01
JP5230936B2 (ja) 2013-07-10
CN1784472A (zh) 2006-06-07
CA2522746A1 (fr) 2004-11-18
US20040220339A1 (en) 2004-11-04
EP1620508A2 (fr) 2006-02-01
EP1620508B1 (fr) 2006-11-15
KR100989702B1 (ko) 2010-10-26

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